Method for manufacturing structural member

Abstract

To provide a method for manufacturing a structural member capable of manufacturing a high-quality structural member by easily joining extruded materials to each other while suppressing complication of a manufacturing process.SOLUTION: A method for manufacturing a structural member includes the steps of: disposing extruded panels 11A to 11D to be joined to each other on a base plate 31; inserting jig plates 35 from both ends of the extruded panels into respective hollow portions 13 adjacent to edge portions of the respective extruded panels 11A to 11D, pulling the adjacent jig plates 35 to each other and butting the edge portions of the extruded panels 11A to 11D; connecting the jig plates 35 pulled to each other by a connecting member 37; fixing the jig plates 35 to the base plate 31; joining the edge portions butted against each other on the front surface side of the extruded panels 11A to 11D to each other; releasing fixation of the jig plates 35 to the base plate 31; reversing the extruded panels 11A to 11D to fix the jig plates 35 to the base plate 31; and joining the edge portions to each other on the back surface side of the extruded panels 11A to 11D.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a structural member.

Background Art

[0002] Conventionally, there has been a demand for improving the safety of vehicle occupants, and for this purpose, the strength of the vehicle body has been improved. On the other hand, against the backdrop of the intensification of problems such as global warming, the movement to improve the fuel efficiency of automobiles has been accelerating. It is known that weight reduction of the vehicle body is effective for improving fuel efficiency. In addition, for the above-described environmental improvement, the development of vehicles that run on electricity (including electric vehicles, hybrid vehicles, etc.) and devices such as self-propelled robots has been progressing. In a battery system mounted on such a vehicle or device, a configuration may be adopted in which a large number of batteries (cells, battery cells) are housed in a battery tray made of a structural member in which aluminum extrusions are joined.

[0003] Patent Document 1 discloses, as a technique for joining hollow members, enclosing a fluid or granular material inside each hollow member and applying pressure in the direction of abutting against the abutting wall of each hollow member from inside each hollow member while friction stir joining the hollow members.

[0004] Patent Document 2 also discloses a technique of welding a processed portion of a metal thin plate having an L-shaped end while sandwiching it with a jig composed of a disc-shaped roll.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, in the technology described in Patent Document 1, since a fluid or a fluid substance is enclosed inside the hollow material, the equipment cost increases. Further, in the technology described in Patent Document 2, since welding is performed while sandwiching the vicinity of the welded portion in the processing portion with a disk-shaped roll, the joining operation is complicated. Further, when joining the front and back of the butting portion, in the technologies described in Patent Documents 1 and 2 above, the members to be joined must be temporarily removed from the equipment, re-aligned, and then attached to the equipment, which requires time and effort for the joining operation.

[0007] Therefore, an object of the present invention is to provide a method for manufacturing a structural member that can easily join extruded materials to each other while suppressing complication of the manufacturing process and manufacture a high-quality structural member.

Means for Solving the Problems

[0008] The present invention has the following configuration. A manufacturing method for manufacturing a structural member by butting and joining the edges of a plurality of extruded panels made of extruded materials having hollow portions, a jig plate insertion step of arranging the extruded panels to be joined to each other on a base plate and inserting a jig plate into each of the hollow portions adjacent to the edges of the respective extruded panels from both ends of the extruded panels; a butting step of pulling adjacent jig plates toward each other to butt the edges of the extruded panels and connecting the pulled jig plates to each other with a connecting member; a first fixing step of fixing the jig plate to the base plate; a first joining step of joining the edges butted against each other on the surface side of the extruded panel opposite to the base plate; a fixing release step of releasing the fixing of the jig plate to the base plate; a second fixing step of inverting the extruded panel and fixing the jig plate to the base plate; a second joining step of joining the edges on the back surface side of the extruded panel; including a method for manufacturing a structural member.

Advantages of the Invention

[0009] According to the present invention, while suppressing the complication of the manufacturing process, the extruded materials can be easily joined to manufacture a high-quality structural member.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

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Figure 6

Figure 7

Figure 8

Figure 9A

Figure 9B

Figure 9C

Figure 9D

Figure 9E

Figure 9F

DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view of a structural member 100 manufactured by the manufacturing method of the structural member of this example. FIG. 2 is an enlarged front view of a part of the structural member 100 shown in FIG. 1.

[0012] As shown in FIG. 1, the structural member 100 manufactured by the manufacturing method of the structural member according to this configuration example is a plate-shaped structure, and is composed of a plurality (four in this example as an example) of extrusion panels 11A to 11D. The structural member 100 is configured by joining the edges facing each other along the extrusion direction of the extrusion panels 11A to 11D.

[0013] As the extrusion panels 11A to 11D, plate-shaped extruded materials made of aluminum or an aluminum alloy can all be used. As the aluminum alloy constituting the extrusion panels 11A to 11D, aluminum alloys such as 5000 series, 6000 series, and 7000 series according to JIS or AA standards are preferable in terms of having excellent strength and being able to be made thinner. These hollow extruded shapes of aluminum alloy can preferably be manufactured by appropriately combining quality control processes such as casting (DC casting method or continuous casting method), homogenization heat treatment, hot extrusion, solution treatment and quenching treatment, and artificial aging treatment if necessary. According to this, the structural member 100 can be configured to have a high strength while being lightweight.

[0014] One or a plurality of hollow portions 13 are formed in the center of the extrusion panels 11A to 11D in the thickness direction. The extrusion panels 11A to 11D are, for example, thin plates with a thickness of 15 mm or less. The thickness of the hollow portion 13 of the extrusion panels 11A to 11D is preferably about half of the thickness of the extrusion panels 11A to 11D.

[0015] The structural member 100 shown in Fig. 2 is joined at the joint portion 21 where the edges of the extrusion panels 11B and 11C are butted against each other. Similarly, it is also joined between the extrusion panel 11A and the extrusion panel 11B, and between the extrusion panel 11C and the extrusion panel 11D. The extrusion panels 11A to 11D have protruding pieces 15 and stepped portions 17 at the edges on the side of the joint portion 21 facing each other. These pairs of protruding pieces 15 are overlapped with each other in the plate thickness direction. And the extrusion panels 11A to 11D are such that at each joint portion 21, the protruding piece 15 of one extrusion panel abuts against the wall portion 17a forming the stepped portion 17 of the other extrusion panel, and the butting portions on the front and back are joined. Thereby, the joint portion 21 has a first joint portion 23 formed on the front surface side which is one surface, and a second joint portion 25 formed on the back surface side which is the other surface. Each of the first joint portion 23 and the second joint portion 25 is a joint site formed by various joining methods such as friction stir welding, MIG welding or laser welding, for example.

[0016] In the structural member 100 of this configuration, the butting portions between the extrusion panels 11A to 11D on the front and back are joined with a well-balanced and stable joining strength at the first joint portion 23 on the front surface side and the second joint portion 25 on the back surface side. Therefore, sufficient strength can be ensured at the joint portion 21 of the structural member 100 and its periphery.

[0017] Next, the jig 30 used when joining the above-described extrusion panels 11A to 11D to each other will be described. Fig. 3 is a perspective view for explaining the jig 30 used in the manufacturing method of the structural member of this example. Fig. 4 is a plan view of the jig 30 shown in Fig. 3. Fig. 5 is a cross-sectional view taken along the line V-V in Fig. 4. As shown in Figs. 3 to 5, the jig 30 has a base plate 31, a wedge plate 33, a jig plate 35, and a connecting member 37.

[0018] FIG. 6 is a plan view showing a state in which the wedge plate 33 is disposed in the hollow portions 13 of the extrusion panels 11A to 11D on the base plate 31. FIG. 7 is a plan view showing a state in which a jig plate 35 is further inserted into the hollow portions 13 of the extrusion panels 11A to 11D shown in FIG. 6. FIG. 8 is a cross-sectional view taken along line VIII-VIII in FIG. 4. In FIGS. 6 and 7, the inside of the hollow portion 13 is illustrated through virtual windows W1 and W2 indicated by two-dot chain lines.

[0019] The base plate 31 shown in FIG. 6 is formed in a flat plate shape with a smooth upper surface. The base plate 31 is rectangular in plan view, and extrusion panels 11A to 11D to be joined to each other are arranged along the longitudinal direction of the base plate 31 on its upper surface. These extrusion panels 11A to 11D are aligned in a state where the extrusion directions are aligned in one direction. In the vicinity of the edge portion in the short side direction of the base plate 31, bolt holes 31a each composed of a plurality of female screws are formed at predetermined intervals in the longitudinal direction of the base plate 31.

[0020] The wedge plate 33 is a plate material formed in a substantially triangular shape in plan view. The wedge plate 33 is inserted into the hollow portions 13 of the extrusion panels 11A to 11D and is disposed at a substantially central position in the extrusion direction of the extrusion panels 11A to 11D. The arrangement position of the wedge plate 33 at this time does not have to be exact. The wedge plate 33 has a contact surface 41 and a pair of guide surfaces 43. The pair of guide surfaces 43 are inclined surfaces that incline in a direction approaching the contact surface 41 gradually from the center to both ends of the wedge plate 33.

[0021] As shown in FIG. 7, the jig plate 35 is formed in a long plate shape. The jig plate 35 is inserted from both ends of the hollow portion 13 where the wedge plate 33 is inserted and arranged in advance toward the central position in the extrusion direction of the hollow portion 13. The jig plate 35 has a pressing surface 45 and a tapered surface 47. The tapered surface 47 is an inclined surface that inclines in a direction approaching the pressing surface 45 gradually toward the tip of the jig plate 35. Further, a through hole 35a penetrating through the front and back is formed on the rear end side of the jig plate 35. Each through hole 35a communicates with the bolt hole 31a (FIG. 6) of the base plate 31 in a state where the jig plate 35 is inserted into the hollow portion 13 of the extrusion panels 11A to 11D. Bolts 39 are respectively inserted into the through holes 35a, and the inserted bolts 39 are fastened to the bolt holes 31a of the base plate 31. Thereby, as shown in FIGS. 3 to 5, the jig plate 35 is fixed to the base plate 31.

[0022] Also, as shown in FIG. 3, a connecting block portion 49 is connected to the rear end portion of the jig plate 35. The connecting block portion 49 is disposed outside the edge portion in the short side direction of the base plate 31 in a state where the jig plate 35 is inserted into the hollow portion 13 of the extrusion panels 11A to 11D. As shown in FIG. 8, a connecting hole 49a penetrating in a direction orthogonal to the insertion direction into the hollow portion 13 along the surface direction of the jig plate 35 is formed in the connecting block portion 49.

[0023] As shown in FIGS. 3 and 4, the connecting member 37 includes a plurality of space holding pipes 51A to 51G, a pair of connecting rods 53, and a pair of fastening members 55.

[0024] As shown in FIGS. 3 and 8, the space holding pipes 51A to 51G are disposed between the connecting block portions 49 connected to the jig plate 35 inserted into the hollow portion 13 of the extrusion panels 11A to 11D and outside the pair of connecting block portions 49 respectively arranged at both longitudinal ends of the base plate 31. These space holding pipes 51A to 51G communicate with the connecting holes 49a of the connecting block portions 49 of each jig plate 35.

[0025] The connecting rod 53 is formed from a rod having male threads at both ends. The connecting rod 53 is inserted into the spacing pipes 51A to 51G that communicate with each other and the connecting holes 49a of the connecting block portion 49, respectively.

[0026] The fastening member 55 is made of, for example, an angle bar and is disposed on both sides of the base plate 31. Eye bolts 57 having annular portions 57a are fixed to both ends of the fastening member 55 (see FIGS. 3 and 4). Insertion holes 55a are formed near both ends of the fastening member 55, and the ends of the connecting rod 53 are inserted into the respective insertion holes 55a. Then, nuts 59 are fastened to the male threads at the ends of the connecting rod 53 inserted into the insertion holes 55a. Thereby, the plurality of connecting block portions 49 are fixed at intervals corresponding to the spacing pipes 51A to 51G, and the plurality of jig plates 35 are arranged so as to respectively protrude from the connecting block portions 49 toward the extrusion panels 11A to 11D.

[0027] Next, a procedure for manufacturing the structural member 100 using the above jig 30 will be described. FIGS. 9A to 9G are explanatory views showing a procedure for joining the extrusion panels 11A to 11D to form the structural member 100.

[0028] (Jig plate insertion step) First, the extrusion panels 11A to 11D to be joined to each other are arranged on the base plate 31 along their extrusion directions. Wedge plates 33 are respectively inserted into the hollow portions 13 adjacent to the edges on the joint portion 21 side of these extrusion panels 11A to 11D, and each wedge plate 33 is arranged at a substantially central position in the extrusion direction (see FIG. 6). The wedge plates 33 are arranged in the hollow portions 13 with their contact surfaces 41 facing the opposite side to the butting side of the extrusion panels 11A to 11D, and the contact surfaces 41 are brought into contact with the inner surfaces of the hollow portions 13 facing the contact surfaces 41.

[0029] Next, as shown in FIG. 9A, the jig plates 35 are inserted into the hollow portions 13 adjacent to the edges on the joint portion 21 side of the extrusion panels 11A to 11D on the base plate 31 from both ends in the extrusion direction of the extrusion panels 11A to 11D. At this time, the pressing surfaces 45 of the respective jig plates 35 are inserted into the hollow portion 13 facing the butting side of the extrusion panels 11A to 11D. Further, the jig plates 35 inserted into the hollow portion 13 are pushed toward the center in the extrusion direction of the hollow portion 13 (see FIG. 7). By doing so, the tapered surface 47 of the jig plate 35 abuts against and slides on the guide surface 43 of the wedge plate 33. As a result, the jig plate 35 is pressed against the inner surface on the butting side in the hollow portion 13.

[0030] (Butting process) As shown in FIG. 9B, the space maintaining pipes 51A to 51G are arranged between the connecting block portions 49 and on the outside of the connecting block portions 49 arranged at both ends, and the connecting rods 53 are inserted through the connecting holes 49a of the space maintaining pipes 51A to 51G and the connecting block portions 49 of the jig plates 35 which communicate with each other. Then, the fastening members 55 are arranged on both sides in the longitudinal direction of the base plate 31, and the end portions of the connecting rods 53 are inserted through the insertion holes 55a of the fastening members 55 and fastened with nuts 59. By doing so, the intervals between the plurality of jig plates 35 are connected at intervals set to a preset length dimension by the space maintaining pipes 51A to 51G.

[0031] Then, the jig plates 35 adjacent to each other with the joint portion 21 interposed therebetween are attracted to each other by the sliding of the guide surface 43 and the tapered surface 47, and the spaces between the extrusion panels 11A and 11B, between the extrusion panels 11B and 11C, and between the extrusion panels 11C and 11D are respectively pressed and contracted by these jig plates 35, and the edges of the extrusion panels 11A to 11D are brought into a state of abutting against each other. The plurality of extrusion panels 11A to 11D are integrated by the connecting member 37 while being maintained in this state.

[0032] (First fixing process) Next, insert the bolt 39 into the through hole 35a of the jig plate 35, fasten it to the bolt hole 31a of the base plate 31, and fix the jig plate 35 to the base plate 31 (see Fig. 4). In this way, by fixing the jig plate 35 to the base plate 31, the extrusion panels 11A to 11D integrated by the connecting member 37 are pressed against the base plate 31 and arranged in a smooth state with respect to each other.

[0033] (First joining step) As shown in Fig. 9C, the joint part 21 where the edges of the extrusion panels 11A to 11D are butted against each other is joined on the surface side (for example, the upper surface side) by various joining methods such as friction stir welding, MIG welding, or laser welding. As a result, a first joint part 23 is formed in the joint part 21 of each of the extrusion panels 11A to 11D, and they are joined to each other on the surface side.

[0034] (Fixing release step) Loosen the bolt 39 that fixes the jig plate 35 to release the fixing of the jig plate 35 to the base plate 31, and remove the extrusion panels 11A to 11D integrated by the connecting member 37 from the base plate 31.

[0035] (Second fixing step) As shown in Fig. 9D, invert the extrusion panels 11A to 11D joined on the surface side together with the connecting member 37 integrally. At this time, hook a hook of a crane or the like on the annular part 57a of the eyebolt 57 fixed to both ends of the fastening member 55, and the extrusion panels 11A to 11D can be easily inverted by lifting them with a crane or the like together with the connecting member 37. Then, as shown in Fig. 9E, place the extrusion panels 11A to 11D removed from the base plate 31 and inverted back on the base plate 31, insert the bolt 39 into the through hole 35a of the jig plate 35, and fasten it to the bolt hole 31a of the base plate 31 to fix the jig plate 35 to the base plate 31. In this way, by fixing the jig plate 35 to the base plate 31, the extrusion panels 11A to 11D integrated by the connecting member 37 are pressed against the base plate 31, the warp generated when joining the surface sides is restored, and they are arranged in a smooth state.

[0036] (Second joining step) As shown in FIG. 9F, on the back side of the extrusion panels 11A to 11D, the joint part 21 is joined by various joining methods such as friction stir welding, MIG welding, or laser welding, and a second joint part 25 is formed on the joint part 21 of the extrusion panels 11A to 11D. In this way, the plurality of extrusion panels 11A to 11D become the structural member 100 in which the joint part 21 is joined on the front and back. Then, loosen the bolt 39 to release the fixing of the jig plate 35 to the base plate 31, and remove the connecting member 37, the jig plate 35, and the wedge plate 33 from the structural member 100.

[0037] As described above, according to the manufacturing method of the structural member according to this example, by pulling the jig plate 35 inserted into the hollow part 13, the edges of the extrusion panels 11A to 11D are butted against each other, and this butted part can be easily joined from both the front and back sides. Also, by utilizing the hollow part 13 formed in the extrusion panels 11A to 11D and butting and joining the edges of the extrusion panels 11A to 11D by the jig plate 35 inserted into this hollow part 13, the manufacturing cost can be suppressed compared to the case of using a complicated device or mechanism. That is, a high-quality structural member 100 in which the extrusion panels 11A to 11D are joined on the front and back can be easily manufactured while suppressing the cost.

[0038] Further, since the jig plate 35 is pressed by the guide surface 43 of the wedge plate 33 in the butting direction of the edges of the extrusion panels 11A to 11D, when the adjacent jig plates 35 are pulled toward each other, the edges of the extrusion panels 11A to 11D can be butted against each other in a well-balanced manner. Thereby, a high-quality structural member 100 in which the extrusion panels 11A to 11D are joined on the front and back in a well-balanced manner can be manufactured.

[0039] Moreover, since the tapered surface 47 of the jig plate 35 slides on the guide surface 43 of the wedge plate 33, the jig plate 35 can be smoothly pressed in the butting direction of the edges of the extrusion panels 11A to 11D.

[0040] In the above-described embodiment, the jig plate 35 is fixed to the base plate 31 by the bolt 39. However, the fixing of the jig plate 35 to the base plate 31 is not limited to fastening by the bolt 39, and may be fixed by various fastening methods using clamps, pins, or the like.

[0041] Thus, the present invention is not limited to the above-described embodiment, and it is also contemplated by the present invention that those skilled in the art can make changes and applications based on combining each configuration of the embodiment with each other, the description in the specification, and well-known techniques, and these are included in the scope for which protection is sought.

[0042] As described above, the following matters are disclosed in this specification. (1) A manufacturing method for manufacturing a structural member by butting and joining the edges of a plurality of extrusion panels made of an extruded material having a hollow portion, a jig plate insertion step of disposing the extrusion panels to be joined to each other on a base plate and inserting a jig plate from both ends of the extrusion panels into the respective hollow portions adjacent to the edges of the respective extrusion panels; a butting step of pulling adjacent jig plates toward each other to butt the edges of the extrusion panels against each other and connecting the pulled jig plates to each other by a connecting member; a first fixing step of fixing the jig plate to the base plate; a first joining step of joining the edges butted against each other on the surface side of the extrusion panel opposite to the base plate; a fixing release step of releasing the fixing of the jig plate to the base plate; a second fixing step of inverting the extrusion panel and fixing the jig plate to the base plate; a second joining step of joining the edges on the back surface side of the extrusion panel; A manufacturing method of a structural member including the above. According to the manufacturing method of this structural member, by pulling the jig plate inserted into the hollow portion, the edges of the extrusion panels are butted against each other, and the butted portion can be easily joined from both the front and back sides. Further, by utilizing the hollow portion formed in the extrusion panel and butting and joining the edges of the extrusion panel by the jig plate inserted into the hollow portion, the manufacturing cost can be suppressed as compared with the case of using a complicated apparatus or mechanism. That is, a high-quality structural member in which the extrusion panels are joined back to back can be easily manufactured while suppressing the cost.

[0043] (2) In the jig plate insertion step, a wedge plate having a guide surface inclined in the butting direction of the edges of the extrusion panel toward the insertion direction of the jig plate is disposed inside the hollow portion adjacent to the edge, and when the jig plate is inserted, the jig plate is pressed in the butting direction by the guide surface of the wedge plate. The manufacturing method of the structural member according to (1). According to the manufacturing method of this structural member, since the jig plate is pressed in the butting direction of the edges of the extrusion panel by the guide surface of the wedge plate, when the adjacent jig plates are pulled toward each other, the edges of the extrusion panel can be butted against each other in a well-balanced manner. Thereby, a high-quality structural member in which the extrusion panels are joined back to back in a well-balanced manner can be manufactured.

[0044] (3) The jig plate has a tapered surface inclined in a direction opposite to the guide surface of the wedge plate, and when the tapered surface slides on the guide surface, it is pressed in the butting direction. The manufacturing method of the structural member according to (2). According to the manufacturing method of this structural member, when the tapered surface of the jig plate slides on the guide surface of the wedge plate, the jig plate can be smoothly pressed in the butting direction of the edges of the extrusion panel.

Explanation of reference numerals

[0045] 11A, 11B, 11C, 11D Extrusion panel 13 Hollow portion 31 Base plate 33 Wedge plate 35 Fixture plate 37 Connecting member 43 Guide surface 47 Tapered surface 100 Structural member

Claims

1. A manufacturing method for manufacturing a structural member by butting and joining the edges of a plurality of extruded panels made of an extruded material having a hollow portion, a jig plate insertion step of arranging the extruded panels to be joined to each other on a base plate and inserting a jig plate from both ends of the extruded panel into each of the hollow portions adjacent to the edges of the respective extruded panels; a butting step of pulling the adjacent jig plates together to butt the edges of the extruded panels and connecting the pulled-together jig plates with a connecting member; a first fixing step of fixing the jig plate to the base plate; a first joining step of joining the edges butted against each other on the surface side of the extruded panel opposite to the base plate; a fixing release step of releasing the fixing of the jig plate to the base plate; a second fixing step of inverting the extruded panel and fixing the jig plate to the base plate; a second joining step of joining the edges on the back side of the extruded panel; including a manufacturing method of a structural member.

2. In the jig plate insertion step, a wedge plate having a guide surface that inclines in the butting direction of the edges of the extruded panel toward the insertion direction of the jig plate is disposed inside the hollow portion adjacent to the edge, and when the jig plate is inserted, the guide surface of the wedge plate presses the jig plate in the butting direction. The manufacturing method of a structural member according to Claim 1.

3. The jig plate has a tapered surface that inclines in a direction opposite to the guide surface of the wedge plate, and the tapered surface slides on the guide surface to be pressed in the butting direction. The manufacturing method of a structural member according to Claim 2.

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